EP3886266B1

EP3886266B1 - Electrical connector with a mate assist system

Info

Publication number: EP3886266B1
Application number: EP20166374.7A
Authority: EP
Inventors: Frédéric MENEZ; Jean Fabre
Original assignee: Aptiv Technologies Ltd
Current assignee: Aptiv Technologies Ltd
Priority date: 2020-03-27
Filing date: 2020-03-27
Publication date: 2023-08-30
Anticipated expiration: 2040-03-27
Also published as: US20210305749A1; US11489286B2; CN113451821A; EP3886266A1; JP2021158118A

Description

Field of the Invention

The invention relates to an electrical connector and, more particularly, to a system for mating two electrical connectors with each other.

Brief Description of Prior Developments

It is known to use mate-assist systems on electrical connectors, in particular when such connectors are used in automotive applications, and especially where either a high number of input/output (I/O) connections per connector are required or where large sections of terminals are required for high power connections. An example of a connector with a mate assist system is disclosed in the patent US5873745 . Another example of connector with a different mate assist system is disclosed in the patent application EP1929588A2 .
Such an electrical connector comprises:

electrical terminals;
a housing having the electrical terminals accommodated therein; and
a mate assist system for assisting in mating the electrical connector to a mating electrical connector, the mate assist system comprising
- o an user actuatable member longitudinally slidably mounted on the housing so as to slide, along an operating direction, between a rear position and a forward position, the user actuatable member comprising a rack section extending parallel to the operating direction,
- o a cam member rotatably mounted to the housing, comprising a cam slot for receiving a mounting pin extending from a side of a mating electrical connector, the cam member having a gear section with teeth engaging said rack section, the engagement of the teeth with the rack section resulting in the rotation of the cam member in a direction of rotation, when the user actuatable member is actuated from the rear position to the forward position.

Further, JP2011253655A discloses a mate assist system with two rotatable cam members. When a high number of wires or cables are connected to the terminals and/or when cables with a large section are connected to the terminals, the cable harness becomes quite rigid. Further, the cables may be short and/or sometimes there is not much room around the connector and the mating connector. Then the bending of the cables may be difficult and as a consequence, it can be difficult to find a proper alignment of the connector and the mating connector along the mating direction.
Further, as schematically illustrated on Figure 8, for an easy mating of the connector 1 with a mating connector 2, there are small clearances between their housings. With the connectors of the prior art, the engagement of the cam member 30 mounted on the connector 1 with the mounting pin 10 extending from the mating connector 2 results in efforts, only on one side of the connectors 1, 2, that rock and tilt the connector 1 with respect to the mating connector 2 (see arrow T). As consequences, not only is the mating of the connectors 1, 2 less easy (resulting from high efforts generated by the connector misalignment during the mating phase), but the reliability and the quality of the electrical contact between the terminals, as well as the reliability of possible sealing means, are not optimized due to the fact that the connector 1 and the mating connector 2 may not be well aligned. Similarly, when the electrical connector 1 and the mating connector 2 are EMI shielded, the shielding continuity can also be deteriorated.
An aim of the disclosure is to propose a connector and/or a connector assembly that mitigate at least partially the problems encountered with the prior art connectors.

Summary of the invention

In accordance with one embodiment, an electrical connector according to claim 1 is provided.
Thanks to the engagement of a cam member and a mounting pin, symmetrically arranged, on opposite sides of the connectors, the mating forces that draw the connectors towards and into each other are the same on both these opposite sides. Further, as a consequence of the opposed rotation directions of the cam members, the torque applied on one face of the housing is balanced by the torque applied on the opposite face. Therefore, any possible rock and tilt the connector with respect to the mating connector is cancelled. Hence, the connector and the mating connector slide into each other respectively in parallel directions.
Other features of this connector are mentioned in the dependent claims, considered separately from one another, or each one considered in combination to one or several other features.
In accordance with another embodiment, an electrical connector assembly according to claims 8 or 9 is provided.

Brief description of the drawings

The foregoing aspects and other features of the disclosure are explained in the following description, taken in connection with the accompanying drawings, wherein:

Fig. 1 is a perspective view of two electrical connectors used to form an electrical connector assembly, the two electrical connectors being mated;
Fig. 2 is a perspective view of the two electrical connectors of the connector assembly shown in Fig. 1, the two electrical connectors being unmated;
Fig. 3 is a perspective view of the user actuatable member used in the connector assembly shown in Figs. 1 and 2;
Fig. 4 is schematic diagram of a rack section and a cam member when the user actuatable member of the connector assembly shown in Figs. 1 and 2 is in the rear position;
Fig. 5 is schematic diagram of a rack section and a cam member when the user actuatable member of the connector assembly shown in Figs. 1 and 2 is in the forward position;
Fig. 6 is a schematic diagram of a rack section and a cam member when the user actuatable member of the connector assembly shown in Figs. 1 and 2 is in the forward position; and locking means are in a locking position;
Fig. 7 is a schematic diagram of a rack section and a cam member when the user actuatable member of the connector assembly shown in Figs. 1 and 2 is in the forward position, the rack section and cam member being arranged on the face of the connector opposite to the one on which are arranged the rack section and the cam member shown on Figs. 4 to 6;
Fig. 8 is a perspective view illustrating the rocking movement of the prior art connectors.

Detailed description

An example of a connector assembly 100 is shown on Figs. 1 and 2. This connector assembly 100 comprises a connector 1 and a mating connector 2 or counter-connector. The connector 1 and mating connector 2 are intended to transmit electrical currents having an intensity ranging from 250 Amps to 600 Amps for example. On Fig. 1, the connector 1 and the mating connector 2 are mated, the user actuatable member 20 is in the forward position. On Fig. 2, the connector 1 and the mating connector 2 are unmated, the user actuatable member 20 is in the rear position.
The mating connector 2 is for example a male connector with a dielectric housing 3 accommodating two male power terminals 4 extending longitudinally parallel to an operating or mating direction OD. Each terminal 4 has a linking end 5 for a connection with a busbar or a cable. Each terminal 4 also has a connection end (not shown) intended to be mated with a female power terminal (not shown) accommodated in the housing 10 of the connector 1. The mating connector 2 also comprises interlock terminals (not shown) electrically linked to signal wires 6.
The housing 3 accommodates each one of the male power terminals 4 in a separate cavity 7. The housing 3 comprises a flange 8 for mounting the mating connector 2 onto a wall, a box or any other equipment. The housing 3 comprises walls 9 extending in the operation direction OD, perpendicular to the flange 8. For example, each wall 9 has a generally tubular shape. The housing 3 comprises two mounting pins 10. For example, each mounting pin 9 extends radially perpendicular to the operation direction OD, from a wall 9. The two mounting pins 9 are, for example, aligned to each other in the same axis PD and protrude from the housing 3 on opposite directions along this same axis PD. Shielding and sealing means (not shown) are mounted to the mating connector 2.
The connector 1 comprises a housing 11, a user actuatable member 20 (or slider), two cam members 30 and two female power terminals (not shown) accommodated in the housing 11. The female power terminals are electrically linked to cables (not shown) with cross sections ranging, for example, between 35 to 95 square millimetres (and possibly even higher). Shielding and sealing means are mounted to the connector 1. The housing 11, the user actuatable member 20 and the two cam members 30 are made of dielectric material. The two cam members 30 are identical. This reduces the number of different parts to be manufactured and managed. They can be manufactured in the same mould cavity.
As shown in Fig. 3, the user actuatable member 20 has four walls 21, 22, 23, 24, each one generally extending in planes parallel to a longitudinal central axis CA. The central axis CA is parallel to the operation direction OD. The four walls 21, 22, 23, 24 comprise an upper wall 21, a lower wall 22 and two lateral walls 23, 24. The four walls 21, 22, 23, 24 define a generally rectangular cross-section. Each one of the four walls 21, 22, 23, 24 has an inner surface 21A, 22A, 23A, 24A. Two adjacent walls chosen among the four walls 21, 22, 23, 24 are perpendicular to each other and define a corner. A first rack section 25 is located on the corner between the lower wall 22 and a lateral wall 23. A second rack section 26 is located in an opposite corner, which is between the upper wall 21 and the other lateral wall 24. In other words, the first 25 and second 26 rack sections are located respectively on an inner surface of the user actuatable member 20 and generally symmetrically arranged with regard to the longitudinal central axis CA. The first rack section 25 has teeth 27 extending parallel to the lateral walls 23, 24 in a direction from the lower wall 22 to the upper wall 21. The second rack section 26 has teeth 27 extending parallel to the lateral walls 23, 24 in a direction from the upper wall 21 to the lower wall 22.
The user actuatable member 20 forms a slider which is guided along the operation direction OD with rails 28 slidably engaged in counterpart rails 29 protruding on the outer surfaces of the housing 11 (see Fig. 2). The user actuatable member 20 is slidably mounted to the housing 11, with its upper wall 21, lower wall 22 and lateral walls 23, 24 surrounding the outer surfaces 12 of the housing 11, which are parallel to the operation direction OD.
Each cam member 30 is rotatably mounted onto an outer lateral surface 12 of the housing, between this outer lateral surface 12 and the inner surface 23A or 24A of a lateral wall 23 or 24 of the user actuatable member 20. As shown on Fig. 4, each cam member 30 rotates about a fulcrum 13 outwardly extending from an outer lateral surface 12 facing a lateral wall 23 or 24. Each cam member 30 has a curved cam slot 31 open on an inlet 32. A cam slot 31 receives a mounting pin 10 extending from a side of a mating electrical connector 2. A cam member 30 has a gear section 33 with teeth 34 engaging the teeth 27 of a corresponding rack section 25 or 26.
When the connector 1 is directed toward the mating connector 2, the connector 1 and the mating connector 2 are oriented with regard to each other so that each mounting pin 10 faces a corresponding cam member inlet 32. Advantageously the user holds the connector 1 by the user actuatable member 20 which is in its rear position. When moving the connector 1 and the mating connector 2 further toward each other, each mounting pin 19 enters a cam slot 31. When each mounting pin 10 abuts a stop surface 35 of the cam slot 31, there is a resistance in the movement of the respective housings of the connector and mating connector toward each other. Then, if the user actuatable member 20 is pushed from its rear position towards its forward position, the first 25 and second 26 rack sections engage the teeth 34 respectively of the first and second cam members 30. As a result, each cam member 30 rotates and the mounting pins 10 are urged and guided in their respective cam slot 31.
As shown on Fig. 5, when the user actuatable member 29 is in its forward position each mounting pin 10 abuts the end of a cam slot 31.
Locking means 40 are slidably mounted along a locking direction parallel to the operating direction, between an unlocking position and a locking position.
In the forward position of the user actuatable member 20, the locking means 40 can be pushed from its unlocking position to its locking position, where it engages at least one of the rotatable cam members 30. Then, the rotation of at least one rotatable cam member 30 is blocked by the locking means 40 and this rotatable cam member 30 can no longer rotate. The user actuatable member 20 is locked as well.
The cam members 30 are the same. Consequently, when seen from the same direction, the cam slots 31 are directed in opposite directions (clockwise for one of the cam members, and anticlockwise for the other). The cam member 30 shown on Fig. 6 is shown from the same direction than the cam member 30 shown on Fig. 7. In other words, the cross sections of Figs. 6 and 7 are seen from the same side of the connector 1. Each cam member 30 is mounted on a respective outer surface 12 so that the teeth 34 of a first cam member 30 engage the teeth 27 of the first rack section 25, which is adjacent to the lower wall 22, and the teeth 34 of a second cam member 30 engage the teeth 27 of the second rack section 26, which is adjacent to the upper wall 21.
As shown on Figs 6 and 7, as the user actuatable member 20 is pushed from its rear position to its forward position, a cam member 30 rotates anti-clockwise (see arrow ACW on Fig. 6) whereas the other cam member 30 rotates clockwise (see arrow CW on Fig. 7). As a consequence, the torques acting between each lateral surface 12 and the corresponding mounting pin 10 are opposite to each other. These torques balance each other so that the connector 1 and the mating connector 2 can slide along the mating direction (parallel to the operation direction OD) without rocking or tilting with respect to each other. The connector 1 and the mating connector 2 remain well aligned, the mating force does not increase, the electrical contact between the terminals and the shielding elements are optimized, the risk of a seal pinching is decreased, etc.
Further, due to the double mate-assist system (cam member 30 / mounting pin 10) the robustness of the connector assembly 100 is increased.
Many variations of the embodiment disclosed above can be envisioned. The connector assembly 100 can be with or without EMI shielding, and /or with or without sealing means.
The cam members 30 can be mounted on the user actuatable member 10 and the rack sections 24, 25 can be mounted on the connector housing 11.
The connector 1 can have a third and a fourth rack sections and a third and a fourth rotatable cam members, the third and fourth rotatable cam members being arranged on opposed outer surfaces which are perpendicular to the outer surfaces onto which are mounted the first and second rotatable cam members 30.

Claims

An electrical connector (1) comprising:
electrical terminals;

a housing (11) having the electrical terminals accommodated therein, and

a mate assist system for assisting in mating the electrical connector (1) to a mating electrical connector (2), the mate assist system comprising
- a user actuatable member (20) longitudinally slidably mounted on the housing (11) so as to slide, along an operating direction (OD), between a rear position and a forward position, the housing (11) having four outer surfaces (12) generally extending in planes parallel to a longitudinal central axis (CA) and defining a generally rectangular cross-section,

- a first rack section (25) extending parallel to the operating direction (OD),

- a first rotatable cam member (30) comprising a cam slot (31) for receiving a first mounting pin (10) extending from a first side of the mating electrical connector (2), the first cam member (30) having a first gear section (33) with teeth (34) engaging the first rack section (25), the engagement of the teeth (34) with the first rack section (25) resulting in the rotation of the first cam member (30) in a first direction of rotation (CW or ACW) when the user actuatable member (20) is actuated from the rear position to the forward position,

wherein
- the mate assist system also comprises a second rack section (26) extending parallel to the first rack section (25),

- a second rotatable cam member (30) comprising a cam slot (31) for receiving a second mounting pin (10) extending from a second side of the mating electrical connector (2), the second side being opposite to the first side of the mating electrical connector (2), the second cam member (30) having a second gear section (33) with teeth (34) engaging said second rack section (26), the engagement of the teeth (34) of the second gear section (33) with the second rack section (26) resulting in the rotation of the second cam member (30) in a second direction of rotation (ACW or CW) when the user actuatable member (20) is actuated from the rear position to the forward position, the first direction of rotation (CW) being opposite to the second direction of rotation (ACW) when the first cam member (30) and the second cam member (30) are seen from a same side of the connector (1), wherein the first and second rotatable cam members (30) are each respectively mounted on opposed outer surfaces (12) of the four outer surfaces (12),

characterized in that the first and second rotatable cam members (30) are configured to rotate about an axis that is parallel to a line that joins two terminals.
An electrical connector (1) according to claim 1, wherein housing (11) is made of a single piece.
An electrical connector (1) according to claim 1 or 2, wherein the respective cam slots (31) of the first and second cam members (30) have the same cam race and wherein the first and second cam members (30) rotate about the same axis (13).
An electrical connector (1) according to any preceding claim, wherein the user actuatable member (20) comprises the first and second rack sections (25, 26) and the first and second rotatable cam members (30) are rotatably mounted to the housing (11).
An electrical connector (1) according to claim 4, wherein the user actuatable member (20) has four walls (21, 22, 23, 24) generally extending in planes parallel to a longitudinal central axis (CA) and defining a generally rectangular cross-section, the first and second rack sections (25, 26) being located respectively on an inner surface of the user actuatable member (20) and generally symmetrically arranged with regard to the longitudinal central axis (CA).
An electrical connector (1) according to any preceding claim, wherein the first and second rotatable cam members (30) are identical.
An electrical connector (1) according to any preceding claim, comprising locking means (40) slidably mounted along a locking direction parallel to the operating direction (OD), between an unlocking position and a locking position wherein the locking means (40) engages at least one of the first and second rotatable cam members (30) when the user actuatable member (20) is in its forward position.
An electrical connector assembly (100), comprising a connector (1) according to any preceding claim and a mating connector (2), the first and second mounting pins (10) being respectively arranged on opposite outer surfaces of the mating connector housing (3).
An electrical connector assembly (100) according to claim 8, wherein the first and second mounting pins (10) protrude on opposite directions along a same axis (PD).